Ion-change-responsive switch

ABSTRACT

A material, such as polymeric fibers, which change dimensionally in response to increases or decreases in ions such as calcium or magnesium are connected to a first member. A second member is enclosed in a sealed housing and is spaced from and out of direct contact with said first contact. By means of a relationship between the first and second members, such as electrical field, magnetic or electromagnetic, movement of the first member, in response to dimensional changes in the contractile material result in movement of the second member, thereby activating a switch mechanism.

United States Patent 72] lnventors Stephen Lepp Plainsboro Township, Middlesex County; Edward Studley, North Plainfield; Jonas Weiss, Plainfield, NJ.

[2]] Appl. No. 787,947

[22] Filed Dec. 30, 1968 [45] Patented Jan. 19, 1971 [73] Assignee American Standard Inc.

1 New York, N.Y.

a corporation of Delaware [54] ION-CHANGE-RESPONSIVE SWITCH g 24 Claims, 9 Drawing Figs.

[52] US. Cl 200/61.04,

. 210/96 [51] Int. Cl ..1-10lh 36/00 [50] Field of Search 200/61 .04,

84.3; 210/96, (inquired) [56] References Cited UNITED STATES PATENTS 2,748,687 6/1956 Ballard ZOO/61.04

3,114,478 12/1963 Hilkemeyer et al 200/84.3UX 3,163,729 12/1964 Flagg ZOO/61.04 3,250,392 5/1966 Luck 210/96 Primary Examiner-Robert K. Schaefer Assistant Examiner-M. Ginsburg Attorneys-Sheldon 1-1. Parker, Tennes 1. Erstad and Robert G. Crooks ABSTRACT: A material, such as polymeric fibers, which change dimensionally in response to increases or decreases in ions such as calcium or magnesium are connected to a first member. A second member is enclosed in a sealed housing and is spaced from and out of direct contact with said first contact. By means of a relationship between the first and second members, such as electrical field, magnetic or electromagnetic, movement of the first member, in response to dimensional changes in the contractile material result in movement of the second member, thereby activating a switch mechanism.

ION-CHANGE-RESPONSIVE SWITCH CROSS-REFERENCE TO RELATED APPLICATIONS The general mechanism and specific polymeric fibers of the contractile type are described in copending Pat. applications, Ser. No. 728,937 filed May 14, 1968, now abandoned and Ser. No. 505,921, filed Nov. l, I965.

BACKGROUND OF INVENTION 1. Field of the Invention This invention relates to the field of remote operated sivitches, and more specifically, to the movement of a first element such as a magnet in order to open or close a spaced-magnetic field responsive switch.

2. Description of the Prior Art It is known that in the field of water softeners, ion concentration changes, specifically, calcium and magnesium concentration changes can produce dimensional changes in a material. It has been proposed, for example, in U.S. Pat. No. 3,250,392, that such dimensional changes be converted into the opening or closing of a switch'in order to start or stop a regeneration cycle in a water softener- It is proposedin the patent that the contractile material be positioned within the'resin bed of the water softener and be directly linked through the wall of the water softener to a switching mechanism. However, such systems typically operate a fluid pressure on the order of 100 pounds per square inch (p.s.i. The force available from the contractile material would therefore have to be sufficiently great to have a sealing force in excess of I p.s.i. applied it and still be able to move a switch.

Another proposal is to include the switch mechanism within the water softener bed proximate the contractile material. This alternative requires either a sealing arrangement as previously noted if the electrical contacts of the switch are to be shielded from the highly electrically conductive fluid within the water softener. The other alternative, as shown in the patent, simply exposes the switch to the fluid in the water softener. The foregoing structural arrangements have not been found to lend themselves to commercial applications because of the small driving force available from the contractile material and the high electrical conductivities of the fluid within the water softener.

SUMMARY OF THE INVENTION It has now been found that the contractile material can be isolated from theswitching mechanism and can function as a remote actuator.

In accordance with the present invention, and ion responsive control device is provided which includes a first chamber and a second chamber. The first chamber has at least one port and a contractile member is positioned within the first chamber, with one end fixed with respect to the first chamber. A first control member is operatively connected to the other end of the contractile member, such that the control member moves in response to dimensional changes of the contractile member.

The second chamber is fluid-tight and has a second control member positioned therein. The second member is out of direct physical contact with the first control member, but is proximate thereto and is sensitive and responsive to movement of the first control member.

Thus, movement of the contractile member physically moves the first control member, and movement of the first control member produces a remote response in the second control member.

BRIEF DESCRIPTION OF THE DRAWINGS The objects and advantages of the invention will time apparent and will be fully understood from the following description when read in conjunction with the drawings, wherein:

FIG. I is a perspective view, partly in cross section, of a water softener which incorporates a control mechanism in accordance with the present invention;

FIG. 2 is an elevational view, in cross section of the control mechanism of FIG. 1;

FIG. 3 is a schematic illustration of a modification of a control mechanism of the present invention, along with the circuitry for the control; I

FIG. 4 is an elevation view, in cross section of another modification of a housing for the contractile fibers;

FIG. 5 is a cross-sectional view taken along lines 5-5 of FIG.

FIG. 6 is another modification of the structure of FIG. 5; FIG. 7 is another modification of a housing for the contractile fibers;

FIG. 8 is a cross-sectional view of a still further modification of a contractile fiber housing; and FIG. 9 is a cross-sectional view of another modification of a contractile fiber housing.

DESCRIPTION OF THE PREFERRED EMBODIMENTS For convenience invdescribing the invention, reference will be made to the use of the control mechanism in conjunction with a water softener and the contractile material will be described as being fibers. However, it should be understood that the control mechanism can have many applications, as for example in controlling a purification system for a swimming pool, which system is responsive to such parameters as pH, chlorine concentration, or process controls in general, and the contractile material can be in the form of ribbons, sheet rods, or the like. The use of a contractile material in the form of fibers is preferred because this form gives the highest ratio of surface to mass.

As shown in FIG. I, a water softener I0, has a control mechanism 12, positioned within the resin bed 14. The control mechanism is operatively connected to a programmer unit 16, which controls the cycling of the various operations of the water softener.

As shown in FIG. 2, the control 12 includes a contractile fiber housing 20 and a reed switch housing 22.

The housing 20 is in the form of a tube made of a material within the water softener, such as the resin, and the water. The material can conveniently be a polymer such as polyetheylene, lucite, bakelite or the like. A polymer sold under the trade mark Lexan has been found to give the desired results.

The open ends of the tube can besealed in any convenient manner as for example by means of a silicone rubber plug 24 or other sealant or by means of a disc 26 cemented or fused to the tube 20.

An elongated slot 21 is provided in the tube 20, in the region of the contractile fibers 23. A wire screen 25 is positioned over the slot in order to prevent resin or other solid material from getting into the tube 20.

The exact type of screening or protection employed is not critical except to the extent that the pore diameter must be sufficiently small to exclude all of the undesired solid material and must be sufficiently large so that the free flow of fluid between the interior of the water softener and the fibers 23, is not excessively hampered or interferred with. The eddy currents setup by the water softener beads in the region of the slot 21 provides a positive force which causes a constant flow of water past the fibers 23. The closures at the top and bottom of the tube 20 serve to prevent kinetic forces generated by water flow in the bed from moving the magnet 18 and resulting in spurious signals. In this regard it is noted that movement of the magnet 18 must be brought about solely as a result in the fibers changing concentrations of calcium and magnesium ions.

The magnet 18 can be coated with a material such as teflon or with a lubricant in order to minimize the frictional resistance'to movement of the magnet.

A bundle of fibers 23 are employed because of the high ratio of surface to mass obtainable with this form of the contractile material, as compared to ribbons, strips, sheets or the like. Moreover. greater tensile strengths can be obtained with fibers than with other material configurations.

The fiber 23 can be fixed at their upper ends to the upper end of the tube 20, in any convenient manner as for example by being potted in the sealant 24. Similarly. the fibers can be potted at their other end in a cement in order to provide a connection between the magnet l8and the fibers 23.

A reed switch 27 is positioned within a tube which can be of the same polymeric material as tube 20. The reed switch 27 must be located with respect to the magnet 18 in a position such that it will be open when the fibers are at one predetermined length and closed when the fibers are at another predetermined length. The length of the fibers, or the change in the length of the fibers 23 reflect a. particular calcium and magnesium iron concentration within the bed 14.

The reed switch can be potted in a material such as an epoxy in order to fix its position and provide a waterproof seal. Leads 27a and 27b provide the required connection between the programmer and the reed switch 27.

In a typical application, the presence of hard water causes the fibers to contract, raising the magnet 18 and closing the reed switch 27. The closing of the reed switch 27 causes a timing motor to be turned on thereby starting a regeneration cycle.

If desired. a timing system can be employed which permits the regeneration to take place only during certain predetermined times of the day thus limiting the regeneration to minimum use periods. In such a case, the position of the reed switch 27 and magnet 18 in the bed should be such that the regeneration signal is given well before the resin bed is exhausted. A sufficient reserve should be provided so as to take into account the maximum usage which might be encountered during the time delay period. If desired, the fibers can be supported in the tube 20, by means of an adjustable support which permits the relative adjusting of the positions of the magnet and the reed switch in order to permit the reserve capacity of the water softener to be adjusted in accordance with the needs of the particular user.

The control mechanism can be an electrical device as shown in FIG. 3. An iron core 38 is suspended from the sensor fibers 23 so that it hangs inside an electrically energized coil 37. When the fibers contract the iron bar is drawn up into a second coil 39, positioned just above the first coil 37, thus energizing the second coil. The rectified current from the second coil operates a relay to control the regeneration of the water softener. This arrangement has particular value for use as a proportional control because the voltage induced in the upper coil 39 will depend upon the extent to which the iron core 38 has entered the coil 39. Contraction of the fibers 23 brings about the movement of iron core'38 form a position within the lower coil 37 to a position between the upper coil 39 and the lower coil 37. A voltage is constantly applied to the lower coil 37 and as the iron core 38 moves upwardly, a greater voltage is induced in the upper coil 39. The circuitry of FIG. 3 provides for the initiating of the regeneration cycle when the voltage exceeds a predetermined minimum level.

A critical aspect of the instant invention, the manner in which mass transfer is achieved between the water and'the contractile fibers. It is essential that the water which surrounds the fibers represent the true condition of the water at that level of the water softener bed. Stagnation of the water in the region of the fibers precludes the control from responding accurately to change resin conditions.

As previously noted, a straight through type of flow, that is, as shown in FIG. 4, one in which water enters an opening in the top of the tube and exits in the vicinity of the magnet l8 can produce inaccurate readings because the fluid pressure against the magnet results in a tensile stress on the contractile fibers. As shown in FIGS. 5 and 6 respectively the magnet can be provided with a hollow core or noncircular configuration such as the triangular shape of magnet, in order to maximize the clearance between the magnet and the housing 20. As

shown in FIG. 7, a divider 42 can be positioned between the fiber-containing section 41, and the magnet-containing section 43, of the tube 40. The screen 26 permits free movement of the water between the resin bed (not shown) and the fibers 23. It is essential that the movement of the magnet 18 within the chamber 43 be unrestricted. Therefore, the magnet can have a cross section, such as seen in FIG. 5, which differs from that of the chamber 43 in order to provide an adequate fluid clearance between the magnet 18 and the interior walls of the chamber 43. Alternatively, the magnet can have a similar cross section with respect to the chamber 43, but a hollow core as seen in FIG. 5.

It should be understood that an excessive clearance between the magnet 18 and the interior walls of the chamber 43 can result in the magnet tending to have excessive freedom of movement. i

In a system in which a high degree of movement of fluid past the fibers 23 is required, a top inlet can be provided in combination with a divider wall. As shown in FIG. 8, a screen 54 is placed over the open upper end of the tube 50. A curved divider wall 52 tends to guide the fluid out of the section 51, by way of the exit port or slot 55, as indicated by the arrows 56.

The magnet can be in the form of a hollow cylinder so that the clearance between the magnet 58 and the interior of the chamber 53 is controlled by the requirements for the magnet to be guided but not restricted, whereas the open interior of the magnet permits the free and unrestricted movement of fluid within the section 53, so that the movement of the magnet is not dampened by a hydraulic resistance.

In the event that the relationship between the contractile fibers 23 and the fluid is such that fluid movement across the fibers must be enhanced, flow directors, such as curved members 63 and 64 as seen in FIG. 9 can be employed. The upper end of the tube 60 can have a flared section 64' so that the fluid flow entrance is maximized or at least enhanced.

It should be understood that the term "contractile material, as employed herein, particularly in reference to fibers 23, is intended to describe a material which reproducibly changes dimensionally, and in particular contracts or expands as the material reacts with some active material in a fluid medium, such as calcium, sodium, or iron ions or the like.

The control mechanism of the instant invention can be used as an indicator or activating mechanism in various applications such as a pH meter and a water-softener control, depending upon the composition of the contractile material.

Although the invention has been described in its preferred forms with a certain degree of particularity, it is understood that the present disclosure of the preferred forms has been made only by way of example, and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention.

We claim:

1 Anion responsive control device comprising:

a. a first chamber, said first chamber having, atleast a first port, screen means completely covering said first port, a contractile member, said member having a first end fixed with respect to said first chamber, a first control member, said first control member being operatively connected to a second end of said contractilelmember and positioned within said first chamber such that said control member moves in response to dimensional changes of said contractile member; and a second chamber, said second chamber being fluid-tight and having therein, a second control member, said second control member being out of direct contact with said first control member, but being proximate said first control member and being movement sensitive with respect to said first c'ontrol member whereby movement of said contractile member physically moves said first control member, and movement of said first control member causes the remote response of said second control member.

2. The structure of claim 1, wherein said first port in said first chamber is positioned proximate said contractile member, between said first end and said first control member.

3. The structure of claim 1, wherein said first control member is a magnet. v

4. The structure of claim 3, wherein said second control member is a reed switch.

5. The structure of claim 3, wherein said magnet is in the form of a hollow cylinder.

6. The structure of claim 1 wherein said control member is enclosed in a fluid-tight housing, and said housing is potted in said fluid-tight chamber, with a polymeric material.

7 The structure of claim 1, wherein said first chamber is provided with a second port, said first port being proximate the fixed end of said contractile member and said second p'ort being proximate said second end of said contractile member.

8. An ion responsive control device comprising:

a. a firstchamber, said first chamber having, at least a first port, a contractile member, said member having a first end fixed with respect to said first chamber, a first control member, said first control member being operatively connected to a second end of said contractile member and positioned within said first chamber such that said control member moves in response to dimensional changes of said contractile member; said first port in said first chamber being approximate said contractile member in order to provide communication between said contractile member and the fluid in which said control device is situated, but said first port being positioned such that fluid flow through said first chamber is not directed toward said first control member; and

b. a second chamber, said second chamber being fluid-tight and having therein, a second control member, said second c ntrol member beingout of direct contact with said first control member but being proximate said first control member and being movement sensitive with respect to said first control element; whereby movement of said contractile member physically moves said first control member, and movement of said first control member causes the remote response of said second control member.

9. The structure of claim 8, wherein said first control member is a magnet.

10. The structure of claim 9, wherein said second control member is a reed switch.

11. The structure of claim 9, wherein said magnet is in the form of a hollow cylinder.

12. The structure of claim 8 wherein said second control member is enclosed in a fluid-tight housing, and said housing is potted in said fluid-tight chamber, with a polymeric material.

13. In a water softener having an ion exchange bed regeneration control which includes a contractile member which is dimensionally responsive to varying ion concentration in said ion exchange bed, the improvement comprising:

said regeneration control having a first chamber, said first chamber in said regeneration control having at least a first port for providing fluid passage means between the interior of said first chamber and said ion exchange bed;

a contractile member, said member having a first end fixed with respect to said first chamber, said first port in said first chamber being positioned proximate said contractile member below said first end;

a first control member, said first control member being operatively connected to a second end of said contractile member and positioned within said first chamber such that said control member moves in response to dimensional changes of said contractile member, a second chamber, said second chamber being fluid-tight and having therein; and

a second control member, said second control member being out of direct contact with said first control member, but being proximate to said first control member, but

being proximate to said first control member and being movement sensitive with respect to said first control member, whereby movement of said contractile member moves said first control member and movement of said 5 first control member causes the remote response of said second control member.

14. The structure of claim 13, wherein said contractile member comprises a bundle of parallel fibers fixed at said first end to said first chamber, and said first control member is fixed to said second end of said contractile member and freely suspended within said first chamber.

15. The structure of claim [3, where said first control member is a magnet.

16. The structure of claim 15, where said second control member is a reed switch.

17. The structure of claim 13, wherein said second control member is enclosed in a fluid-tight housing, and said housing is potted in said second chamber, with a polymeric material.

18. The structure of claim 13 wherein said first chamber is provided with a second port, said first port being proximate the fixed end of said contractile member and said second port being proximate said first control member.

19. In a water softener having an ion exchange bed regeneration control which includes a contractile member which is dimensionally responsive to varying ion concentration in said ion exchange bed, the improvement comprising:

said regeneration control having a first chamber, said first chamber having at least a first port for providing fluid passage means between the interior of said first chamber and said ion exchange bed;

a contractile member, said member having a first end fixed with respect to said first chamber, a first control member, said first control member being operatively connected to a second end of said contractile member and positioned within said first chamber such that said control member moves in response to dimensional changes of said contractile member; r

said first port in said first chamber being proximate said contractile member in order to provide communication between said contractile member and the fluid in which said control device is situated, but said first port being positioned such that fluid flow through said first chamber is not directed toward said first control element; and

a second chamber, said second chamber being fluid-tight and having therein, a second control member, said second control member being out of direct contact with said first control member, but being proximate to said first control member and being movement sensitive with respect to said first control element, whereby movement of said contractile member moves said first control member and movement of said first control member causes the remote response of said second control member.

20. The structure of claim 19, wherein said first control member is a magnet.

21. The structure of claim 20, wherein said second control member is a reed switch.

22. The structure of claim 19 wherein said first chamber is provided with a second port, said first port being proximate the fixed end of said contractile member and said contractile member and said second port being proximate said second end of said contractile member.

23. A fluid switch-control device comprising:

a. a fluid-tight chamber, said fluid-tight chamber having therein a control member, said control member including a pair of electrically energized coils;

b. a contractile member, said member having a first end supported in a fixed position with respect to said fluidtight chamber, and having a second end; and

c. an actuator member, said actuator member being operatively connected to said second end of said contractile member and being positioned proximate said control member, but out of direct contact with said control 24. The structure of claim 23. wherein said contractile member comprises a plurality of parallel fibers. 

1. An ion responsive control device comprising: a. a first chamber, said first chamber having, at least a first port, screen means completely covering said first port, a contractile member, said member having a first end fixed with respect to said first chamber, a first control member, said first control member being operatively connected to a second end of said contractile member and positioned within said first chamber such that said control member moves in response to dimensional changes of said contractile member; and b. a second chamber, said second chamber being fluid-tight and having therein, a second control member, said second control member being out of direct contact with said first control member, but being proximate said first control member and being movement sensitive with respect to said first control member whereby movement of said contractile member physically moves said first control member, and movement of said first control member causes the remote response of said second control member.
 2. The structure of claim 1, wherein said first port in said first chamber is positioned proximate said contractile member, between said first end and said first control member.
 3. The structure of claim 1, wherein said first control member is a magnet.
 4. The structure of claim 3, wherein said second control member is a reed switch.
 5. The structure of claim 3, wherein said magnet is in the form of a hollow cylinder.
 6. The structure of claim 1 wherein said control member is enclosed in a fluid-tight housing, and said housing is potted in said fluid-tight chamber, with a polymeric material. 7 The structure of claim 1, wherein said first chamber is provided with a second port, said first port being proximate the fixed end of said contractile member and said second port being proximate said second end of said contractile member.
 8. An ion responsive control device comprising: a. a first chamber, said first chamber having, at least a first port, a contractile member, said member having a first end fixed with respect to said first chamber, a first control member, said first control member being operatively connected to a second end of said contractile member and positioned within said first chamber such that said control member moves in response to dimensional changes of said contractile member; said first port in said first chamber being approximate said contractile member in order to provide communication between said contractile member and the fluid in which said control device is situated, but said first port being positioned such that fluid flow through said first chamber is not directed toward said first control member; and b. a second chamber, said second chamber being fluid-tight and having therein, a second control member, said second control member being out of direct contact with said first control member but being proximate said first control member and being movement sensitive with respect to said first control element; whereby movement of said contractile member physically moves said first control member, and movement of said first control member causes the remote response of said second control member.
 9. The structure of claim 8, wherein said first control member is a magnet.
 10. The structure of claim 9, wherein said second control member is a reed switch.
 11. The structure of claim 9, wherein said magnet is in the form of a hollow cylinder.
 12. The structure of claim 8 wherein said second control member is enclosed in a fluid-tight housing, and said housing is potted in said fluid-tight chamber, with a polymeric material.
 13. In a water softener having an ion exchange bed regeneration control which includes a contractile member which is dimensionally responsIve to varying ion concentration in said ion exchange bed, the improvement comprising: said regeneration control having a first chamber, said first chamber in said regeneration control having at least a first port for providing fluid passage means between the interior of said first chamber and said ion exchange bed; a contractile member, said member having a first end fixed with respect to said first chamber, said first port in said first chamber being positioned proximate said contractile member below said first end; a first control member, said first control member being operatively connected to a second end of said contractile member and positioned within said first chamber such that said control member moves in response to dimensional changes of said contractile member, a second chamber, said second chamber being fluid-tight and having therein; and a second control member, said second control member being out of direct contact with said first control member, but being proximate to said first control member, but being proximate to said first control member and being movement sensitive with respect to said first control member, whereby movement of said contractile member moves said first control member and movement of said first control member causes the remote response of said second control member.
 14. The structure of claim 13, wherein said contractile member comprises a bundle of parallel fibers fixed at said first end to said first chamber, and said first control member is fixed to said second end of said contractile member and freely suspended within said first chamber.
 15. The structure of claim 13, where said first control member is a magnet.
 16. The structure of claim 15, where said second control member is a reed switch.
 17. The structure of claim 13, wherein said second control member is enclosed in a fluid-tight housing, and said housing is potted in said second chamber, with a polymeric material.
 18. The structure of claim 13 wherein said first chamber is provided with a second port, said first port being proximate the fixed end of said contractile member and said second port being proximate said first control member.
 19. In a water softener having an ion exchange bed regeneration control which includes a contractile member which is dimensionally responsive to varying ion concentration in said ion exchange bed, the improvement comprising: said regeneration control having a first chamber, said first chamber having at least a first port for providing fluid passage means between the interior of said first chamber and said ion exchange bed; a contractile member, said member having a first end fixed with respect to said first chamber, a first control member, said first control member being operatively connected to a second end of said contractile member and positioned within said first chamber such that said control member moves in response to dimensional changes of said contractile member; said first port in said first chamber being proximate said contractile member in order to provide communication between said contractile member and the fluid in which said control device is situated, but said first port being positioned such that fluid flow through said first chamber is not directed toward said first control element; and a second chamber, said second chamber being fluid-tight and having therein, a second control member, said second control member being out of direct contact with said first control member, but being proximate to said first control member and being movement sensitive with respect to said first control element, whereby movement of said contractile member moves said first control member and movement of said first control member causes the remote response of said second control member.
 20. The structure of claim 19, wherein said first control member is a magnet.
 21. The structure of claim 20, wherein said second control member is a reed switch.
 22. The structure of claim 19 whErein said first chamber is provided with a second port, said first port being proximate the fixed end of said contractile member and said contractile member and said second port being proximate said second end of said contractile member.
 23. A fluid switch-control device comprising: a. a fluid-tight chamber, said fluid-tight chamber having therein a control member, said control member including a pair of electrically energized coils; b. a contractile member, said member having a first end supported in a fixed position with respect to said fluid-tight chamber, and having a second end; and c. an actuator member, said actuator member being operatively connected to said second end of said contractile member and being positioned proximate said control member, but out of direct contact with said control member, whereby movement of said contractile member physically moves said actuator member, and movement of said actuator member produces a response in said control member which serves to activate a fluid switch mechanism.
 24. The structure of claim 23, wherein said contractile member comprises a plurality of parallel fibers. 